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Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

  1. INSTALL FRONT DISC 
    1. Align the matchmarks and install the front disc.
      NOTE: When replacing the disc with a new one, select the installation position where the front disc has minimal runout.
      Fig 1: Identifying Matchmarks Location
      G04978385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.
  3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Install the bleeder plug cap to the front disc brake bleeder plug.
  4. INSTALL PISTON SEAL 
    1. Apply lithium soap base glycol grease to a new piston seal.
    2. Install the piston seal to the disc brake cylinder assembly.
  5. INSTALL CYLINDER BOOT 
    1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
    2. Install the cylinder boot to the piston as shown in the illustration.
      Fig 2: Applying Lithium Soap Base Glycol Grease To Piston And Cylinder Boot
      G05408135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DISC BRAKE PISTON 
    1. Install the cylinder boot to the cylinder assembly.
      NOTE: Install the boot securely to the grooves of the cylinder.
    2. Push in the piston by hand and install the boot seal onto the grooves of the piston.
      NOTE: Install the boot securely to the grooves of the piston.
      Fig 3: Pushing Piston By Hand
      G05408136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT 
    1. Apply lithium soap base glycol grease to the seal surfaces of 2 new front disc brake bushing dust boots.
    2. Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
      Fig 4: Applying Lithium Soap Base Glycol Grease To Seal Surfaces
      G04978395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING 
    1. Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
    2. Install the front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.
      Fig 5: Applying Lithium Soap Base Glycol Grease To Front Disc Brake Cylinder Slide Bushing
      G05408138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.
    2. Install the No. 2 front disc brake cylinder slide pin to the bottom side of the front disc brake cylinder mounting.
      Fig 6: Applying Lithium Soap Base Glycol Grease To Sliding Part
      G04978397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin.
      Fig 7: Applying Lithium Soap Base Glycol Grease To Slide Pin
      G05408140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 front disc brake cylinder slide pin.
      Fig 8: Identifying No. 1 Slide Pin
      G04978399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING 
    1. Install the front disc brake cylinder mounting with the 2 bolts.

      Torque: 107 N*m (1090 kgf*cm, 79 ft.*lbf) 

  12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the 4 front disc brake pad support plates.
      Fig 9: Identifying Front Disc Brake Cylinder Mounting With Bolts
      G05408142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT ANTI-SQUEAL SHIM 
    1. Apply disc brake grease to the front anti-squeal shim.
      Fig 10: Identifying Grease Applying Area
      G05408143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When replacing worn pads, the front anti-squeal shims must be replaced together with the pads.
      • Install the shims in the correct positions and directions.
      • Apply disc brake grease to the area that contacts the front anti-squeal shim.
      • Disc brake grease can come out slightly from the area where the front anti-squeal shim is installed.
      • Make sure that disc brake grease is not applied onto the lining surface.
    2. Install the 2 front anti-squeal shims and the 2 pad wear indicators to each pad.
      NOTE: Install the pad wear indicators in the correct positions and directions.
  14. INSTALL FRONT BRAKE PAD 
    1. Install the 2 brake pads with front anti-squeal shims to the front disc brake cylinder mounting.
      Fig 11: Identifying Front Brake Pad Installation Position
      G05408144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 anti-squeal springs to the front disc brake pads.
      NOTE:
      • When replacing worn pads, the front anti-squeal springs must be replaced at the same time.
      • Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.
        Fig 12: Locating Anti-Squeal Springs
        G05408145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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